detailed design package - build4scaleonline bom tools: o build and generate boms in a standard...
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BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org
DetailedDesignPackageModule2ABillofMaterialsandBillofProcess
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Eventhesimplestproductsaretypicallycomplexinstructureo Ifbillofmaterials(BOM),billofprocess(BOP),andengineeringdrawingsarenotcrystalcleartotheinnovatorandthemanufacturer,itcanresultwastedmoneyand/orproductsthatareimproperlyconstructed
o It’scrucialtoknowtheanswersto:— Whatandhowmanycomponentsformtheproduct?— Whatarethesteps/sequenceforfabricaJngtheproduct?— HowcantheproductconJnuetobeproducedeffecJvelyasitscomplexityincreases?
2
Whyisthismoduleimportant?Mo1va1on
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o LearningobjecJveso Producthierarchy,billofmaterials(BOM)o Processplanning,rouJngsheet,billofprocess(BOP)o Engineeringdrawing:— Componentlevel— Assemblylevel— InterpreJngengineeringdrawings
o Casestudies
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ModuleOutline
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o LO1:IdenJfyproducthierarchyandassemblyplano LO2:Developappropriateprocessplanforcomponentso LO3:Assessengineeringdrawingsforcomponents
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LearningObjec1ves
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o TherelaJonshipbetweenBOM,BOP,andengineeringdrawingso BasicterminologyofBOM,BOP,andengineeringdrawingso SomeexisJngonlinetoolstoassistincreaJngaBOMandaBOPo HowtomanageBOMgeneraJonforcomplexproducts
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WhatThisModuleAddresses
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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HowtheyallrelateBOP,BOM,AndDrawings
These3blocksmustbeconsideredsimultaneously!
EngineeringandAssemblyDrawing
BillofMaterials(BOM)
BillofProcess(BOP)
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Engineeringandassemblydrawingprovides:o VisualrepresentaJonofproductandcomponentso Fit,tolerances,andassemblyspecificaJons
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HowtheyallrelateBOP,BOM,AndDrawings
EngineeringandAssemblyDrawing
BillofMaterials(BOM)
BillofProcess(BOP)
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Billofprocess(BOP)addresses:o Processesthatproducetheproductandtheirsequenceo SpecificaJonsandparametersofeachprocessstep
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HowtheyallrelateBOP,BOM,AndDrawings
EngineeringandAssemblyDrawing
BillofMaterials(BOM)
BillofProcess(BOP)
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Howtheyallrelate
Billofmaterials(BOM)addresses:o Componentsformingtheproducto ProducJonJmepercomponent
BOP,BOM,AndDrawings
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EngineeringandAssemblyDrawing
BillofMaterials(BOM)
BillofProcess(BOP)
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Billofmaterials(BOM):ListsquanJJesofcomponents,ingredients,andmaterialsrequiredtomakeaproduct
o Integratesproducthierarchythroughparent/childdelineaJonLevelsofaproduct:o Parent:Enditem(orfinalproduct)o Children:Rawmaterials,components,andsub-assembliesDemandmaydependonproductlevels:o Parent:Independentdemand(externaltothesystem)o Children:Dependentdemand(internaltothesystem)—Demandforanitemdependsonthedemandforitems”higherup”onthetheBOM
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BasicsBillOfMaterials
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
TheBOMprovidesinforma1onabout:o RelaJonshipbetweenitemsatdifferentlevelso QuanJtyofeachitemo LeadTimeofeachitem
Example-ProducthierarchyBillOfMaterials
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Parent(enditem)
Children
Laptop
MonitorQuanJty:1
LeadTime:2weeks
ProcessorQuanJty:1
LeadTime:3weeks
KeyboardQuanJty:1
LeadTime:2weeks
KeysQuanJty:104
LeadTime:1week
CasingQuanJty:1
LeadTime:2days
RawMaterials
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Low-levelcoding(LLC):o AnumberthatidenJfiesthelowestlevelatwhichaspecificitemexistsintheBOM
o AllowsforeasilycompuJngtherequirementsofanitemexisJngatdifferentlevelsoftheBOM
BOMprocessor:o EssenJalcomponentinmostcommercialpackages;maintainstheBOMandautomaJcallyassignsLLCs
o IsessenJalforproductswithlargeBOMs(e.g.,automobileswithapproximately30,000components)
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BOMgeneraConcomponentsBillOfMaterials
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Example–Lowerlevelcoding
o ItemGcanbecodedasLevel2(underB)orLevel3(underE)o LLCconvenJonhasitcodedasLevel3
BillOfMaterials
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ParentChildren
A
CQuanJty:1
LeadTime:2days
BQuanJty:1
LeadTime:1week
Level0
Level1
Level2
GQuanJty:2
LeadTime:5days
Level3
EQuanJty:1
LeadTime:2days
FQuanJty:1
LeadTime:4days
DQuanJty:1
LeadTime:6days
HQuanJty:1
LeadTime:5days
GQuanJty:1
LeadTime:5days
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
OnlineBOMtools:o BuildandgenerateBOMsinastandarduser-friendlyenvironment
o ScantheBOMforduplicatesorredundantpartso GenerateBOMgraphicalrepresentaJonso EnablecollaboraJonacrossanorganizaJonExamples:DragonStandardBOMisafreechromeextensionforcreaJngBOMs.CommercialsoluJonsincludeArenaSoluJons’ProductLifecycleManagement(PLM),MouserElectronics’Forte,andIQMSEnterpriseResourcePlanning(ERP)sohware.
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BillOfMaterialsTools
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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Example–BOMsoFwareBillOfMaterials
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o ProcessplanningistypicallydocumentedonarouJngsheet,alsoknownasabillofprocess(BOP)
Processplanningorganizestheseproduc1on-relatedelements:o MethodsofproducJono Toolingo Fixtureso Machineryo SequenceofoperaJonso ProcessingJmeofoperaJonso Assemblymethods
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BasicsProcessPlanning
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Factorstobeconsideredduringprocessplanning:o Dimensions/sizeo Surfacefinisho Geometricshapeo Toleranceo Materialbeingprocessedo Productvalueandurgencyo ManufacturingcapabiliJesandresourcesavailable
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KeyconsideraConsProcessPlanning
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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ExampleProcessPlanning
Source:hips://www.slideshare.net/GuhanM/process-planning-34794073
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Represent3Dobjectsin2DbyprojecJngtheobject’sshapeontoaplane
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Example-ComponentlevelEngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Correspondingsec1onalview(demonstra1nginternalfeatures)
Indicateswherethesec1onwas
taken
3Dviewofacomponent
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Example–Internalfeatures
EngineeringDrawings
o RepresentinternalfeaturesofcomponentsusingsecJonalviewso ThisisimportanttodisJnguishbetweenhollowcomponentsandsolidcomponents
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Dimensionaltolerances:o Definedastheallowableerrorsonaspecificdimensiono Typicallyexpressedasarangeofvalues(i.e.,thediameterofaholeisexpressedas“3.5inches±0.02,”whichmeansthattheholeisacceptableaslongasitsactualmanufactureddiameterisbetween3.48and3.52inchesindiameter)
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DimensionaltolerancesEngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o RepresenJngdimensionaltolerancesonacomponent’sdrawing
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IntroducContodimensionaltolerancesEngineeringDrawings
+0.2-0.140 0.1 mm40mm
40.239.9 mm
Moredetailedexampleshere-hLps://www.nmri.go.jp/eng/khirata/metalwork/basic/accuracy/index_e.html
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Geometrictolerances:o Definedastheallowableerrorsonshapes,locaJons,andprofiles(asopposedtosizeordimensionaltolerances)
o Specifiedonengineeringdrawingsasaboxwithaleaderconnectedtothefeatureofinterest
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Geometrictolerances
EngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
24
Maintypesofgeometrictolerances
EngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Thisfeaturecontrolframeisreadas:"Thespecifiedfeaturemustlieperpendicularwithinatolerancezoneof0.05diameteratthemaximummaterialcondi1on,withrespecttodatumaxisC
o Inotherwords,thisplacesalimitontheamountofvariaJoninperpendicularitybetweenthefeatureaxisandthedatumaxis.Inadrawing,thisfeaturecontrolframewouldaccompanydimensionaltolerancesthatcontrolthefeaturesizeandposiJon 25
Example-Geometrictolerances
EngineeringDrawings
Source:hips://www.joshuanava.biz/engineering-4/geometric-tolerancing.html
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
26
Example–FlatnessgeometrictoleranceEngineeringDrawings
Engineeringdrawingindica1ngdesiredflatnessoutcome
Translatesinto
Parallelplanes
ToleranceZone
<0.001
Manufacturedproductwithinspecifica1onsoftheengineeringdrawing
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Informa1ononanengineeringdrawingor“blueprint”:o Titleo Versiono Materialo ProjecJontypeo Unitso Scaleo Other(i.e.,assemblyinstrucJons,intellectualproperty,tolerances)
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HowtointerpretthemEngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
28
Example-InterpreCngtheblueprintEngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o AssemblydrawingsareengineeringdrawingrepresentaJonsoftheBOM
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Example–AssembliesEngineeringDrawings
Enlargedonnextslide
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
30
Example–Assemblies(cont.)EngineeringDrawings
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
31
Example1-IniCalwastepipebracketBOPAssemblyMap
PreAsm Pipe Pipe Clamp
Clamp cdi Upper Clamp
Angle
Lower Clamp
Screw flip
Washer Nut cdi Driver Wrench
tighten
Clamp clamp
Drill Motor
Drill Pilot
Cleco
Scribe tool
Mark Loc
Drill Motor
Drill Pilot
scale
unclamp Alodine Prime
Measure
New Clecos
Cleco Plier
Remove Clecos
Scribe Mark Loc
Measure Mark Loc
Driver Loosen Rem Nuts
Rem Screws
Rem Wshrs
Rem Clamp
cdi Rem Pipe
Rem Angle
Unclamp Pipe
Rem Upr
Clamp
Pipe Angle
Clamp Cleco
Drill Motor
Drill Full
Cleco
Insert Cleco
Cleco Pliers
Drill Motor
Drill Full
Rem Harness
Ang
Rem Pipe Ang
Debur Tool
Debur Rag Wipe Solvent
Cleco Pliers
X 2 X 2
X 2
X 2 X 2 X 2
X 2 X 2 X 2 X 2
X 2 X 2
X 2
Harness Angle
Clamp Cleco
Cleco Insert Cleco
X 2 X 2
X 2
X 2
X 2 X 2 X 2 X 2
X 2 X 16
Get Inspector
Inspect Holes
X 8 X 8 X 8
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
32
Example2BOPAssemblyMap
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
33
Example3–CarAssemblyLineBOPAssemblyMap
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
ExampleEngineeringDrawing
34
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Example–BOMonanengineeringdrawingBillOfMaterials
35
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
ExampleBOP,BOM,AndDrawings
BasePlateAssembly
1.BearingMounJngPad
2.MotorMounJngPad
3.MainFrame
4.AngleMounJngBrackets
5.CrossSupports
8.MotorMounJngPad
TheseitemscorrespondtothelinenumberintheBOM
onpreviousslide 36
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Background:o HyperionisdevelopingaLEDbulbthatwillreplacetheconvenJonalhigh-intensitydischarge(HID),metalhalide,andhigh-pressuresodiumbulbsusedinornamentalsidewalklamps.ThebulbreferredtohereastheB1hasdevelopedthroughtwomajoriteraJons,theB1-aandtheB1-b,withnumerousdevelopmentiteraJonsbetweentheversions
37
Casestudy1–LEDlightbulbBOM/BOP
Note:ThroughouttheBuild4Scalemodules,we’llincludeproductcasestudiesthatillustratewhatonecompanyexperiencedastheyweredevelopingtheirproducts.Wehavechangedthecompanynameandanonymizedtheirproduct,butwehopethattheir
experiencewillhelpyouavoidthepipallstheyencounteredandshedlightonthelessonstheylearnedalongtheway.
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o UsingtheBOM,HyperionwasabletoidenJfywhichcomponentswouldprovidethemostoverallvalueforproductcostreducJonanddesignopJmizaJon.
o InsteadoflookingateverysinglecomponentintheBOM,HyperionwasabletofocusitsaienJononafewcomponentsthatwouldgreatlyaffectcostandJme
o Inthiscase,theBOMwasusedtoidenJfycomponenthierarchybasedonthefuncJon,materials,andcostofproducJon
o HyperionwasabletoclearlyidenJfythefanassemblyasaprimetargetforcostreducJonwithapercentageoftotalcostatscaleof43.2%
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Casestudy1–LEDlightbulb(cont.)BillOfMaterials
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
39
Casestudy1–LEDlightbulb(cont.)BillOfMaterials
FanAssembly
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o BycodingtheirproducJonintoarunninglistofprocesses(orBOP)andtrackingiteraJonsusingversioncontrol,thecompanydocumentedchangesintheirprototypeproducJonprocessestolaterbecarriedintoamanufacturingiteraJon
o TheBOPandtheBOMarethefoundaJonuponwhichfurtherproductdevelopmentcanbebuiltfromprototypetomanufacturing.TheywillbeaconJnuoustrunkofinformaJonrunningthroughallfutureiteraJons
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Casestudy1–LEDlightbulb(cont.)
BillOfProcess
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o AstheteambeganproducJonofthelampendcap,thequanJtyofproducJonbegantodictatethemanufacturingprocess
o Thedecisioncamedowntothemanufacturingprocessthathadthelowestcost
o IniJalprototypingwascompletedattheLosAngelesAdvancedCleantechIncubator(LACI)PrototypingCentertoallowforrapiditeraJondevelopment
41
Casestudy1–LEDlightbulb(cont.)ManufacturingProcess
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o AsthedemonstraJonsiteswerecomingonline,HyperionmovedproducJontoasiliconmoldcastcontractortohandletheincreasedquanJJes
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Casestudy1–LEDlightbulb(cont.)ManufacturingProcess
NumberofPartsNeeded
ManufacturingProcess
Produc1onSite
1-100 3DPrinJng PrototypingCenter
50-500 SiliconMoldCasJng Contractor
2,000-10,000 InjecJonMolding Contractor
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Somanytradeoffs—howdoyouevaluate?Materialtradeoffs:o DifferentmaterialsrequiredifferenttoolsandproducJonprocesses,eachwiththeirowntrade-offs
o Reducedcostofmaterialsmaymeanhigherper-piecepricewithvolumeifthenewmaterialrequiresamoreexpensiveproducJonprocess
o Morerobustmaterialsmayrequirelargerinvestmentintoolingandcapitalequipment
o Lighterweightdoesnotnecessarilymeanlessmaterial
SeeModule3BformoredetailsonmaterialselecCon
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TradeoffsScale-UpEffectsOnBOM/BOP
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Manufacturingprocesstradeoffs:o Lowervolumesrequiredifferentmanufacturingprocesstocontroltoolingandcapitalequipmentinvestments
o SwitchtohighvolumewithlesstaktJmeprocessmayrequiremajorinvestmentincapitalequipmentbutlowerper-piecepriceoverJme
SeeModule3Cformoredetailsonmanufacturingprocesses
44
Tradeoffs(cont.)Scale-UpEffectsOnBOM/BOP
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
1.DeterminetheoperaJngenvironment:Industrial/powerplants—thelampwouldexperiencehightemperaturesandvibraJon
2.SummarizeandprioriJzethefuncJonalneedsbasedontheoperaJngenvironment(ideallyquanJfyneeds):— a.Structurallystrong— b.Operateathighheat(500–700°C)
— c.CosteffecJve
3.ExploreyourmaterialopJonsbasedonavailability,generalcost,weight,manufacturability,etc.DetermineopJonstobe:— Polycarbonate— StainlessSteel
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Casestudy2-OutdoorLEDretrofitbulbMaterialSelec1on
FanCenterBodySupport
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
46
Casestudy2-OutdoorLEDretrofitbulb(cont.)MaterialSelec1on
4.WithmaterialselecJonnarroweddownevaluateeachbasedonthreecriteriainstep2
o Stainlesssteel-NotasairacJvebecauseofhighercostandweightbutsJllpreferredduetostrengthandoperaJoninheat
5.Finaldecision:BecauseoftheuniqueoperaJngcondiJons,wepreferredstainlesssteel
o Polycarbonate-AiracJvebecauseit'slowerinweightandcostbutthesearesecondaryfactors
Material Opera1ngT(°C) Strength Weight Cost
Polycarbonate 100 Lower Lighter Lower
Stainlesssteel 800 Higher Heavier Higher
Keydeterminingfactorsarecircledbelow:
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o TheuseofmaterialsandmanufacturingprocessisnotonlydictatedbyvolumebutalsobytolerancerequirementsanddesignprioriJes
Note:DefiniJonofprocessesfoundonthenextpage
47
Scale-UpEffectsOnBOM/BOP
SeeModule3Band3Cformoredetails
Material LowVolume MediumVolume HighVolume
Higherper-piececost,Low-costtooling
Lowerper-piececost,Highertoolingcost
Lowestper-piececost,Highercapitalequipment,
toolingcost
Metal MachinefromBillet,AddiJveMfg
SohTooling(CasJng)
HardTooling(StampingDie,Extrusion)
Plas1c MachinefromBillet,AddiJveMfg
RotaJonalMolding,BlowMolding,Thermoforming
InjecJonMolding,Extrusion,Pultrusion
Composite HandLayup,AddiJveMfg
RTM,VARTM,CompressionMolding
InjecJonMolding,Pultrusion,Filament
Winding
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Resintransfermolding(RTM)isanincreasinglycommonformofmolding,usingliquidcompositehips://www.azom.com/arJcle.aspx?ArJcleID=8620
o VacuumAssistedResinTransferMolding(VARTM)orVacuumInjectedMolding(VIM)isaclosedmold,outofautoclave(OOA)compositemanufacturingprocesships://en.wikipedia.org/wiki/Vacuum_assisted_resin_transfer_molding
o PultrusionisaconJnuousprocessformanufactureofcompositematerialswithconstantcross-secJonhips://en.wikipedia.org/wiki/Pultrusion
o Handlay-upisamoldingprocesswherefiberreinforcementsareplacedbyhandthenwetwithresinhip://www.coremt.com/processes/hand-lay-up/
o CompressionmoldingisaformingprocessinwhichaplasJcmaterialisplaceddirectlyintoaheatedmetalmold,thenissohenedbytheheat,andforcedtoconformtotheshapeofthemoldasthemoldclosesoncemoldingiscompletedexcessflashareremoved,in-ordertogetbestfinishhips://en.wikipedia.org/wiki/Compression_molding
48
DescripConofMoldingMethodsScale-UpEffectsOnBOM/BOP
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
ControllingvariabilityinBOMandBOP:o Addstocost,complexityo Impactsqualitycontrol,inventoryreadiness,partstracking,suppliercontracts
Partsplanning:o Considerapartstrackingsystem(forinventoryordering/controlandqualitytraceability)
o Highlyrecommendaplanforeachpart!Processdocumenta1on:o Workflowprocessmapping(valuestreammapping)o ISOprocessdocumentaJon
49
KeyconsideraConsScale-UpEffectsOnBOM/BOP
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
50
SummaryScale-UpEffectsOnBOM/BOP
BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Generalmoldingresourceguidehip://www.plasJcmoulding.ca/techniques/compression_moulding.htm
51
Resources
Glossary
Module 2A
BOM – Bill of Materials is a list of the raw materials, sub-assemblies, intermediate assemblies,
sub-components, parts and the quantities of each needed to manufacture an end product.
BOP – Bill of Process is a best practices template for production comprised of detailed plans
explaining the manufacturing processes for a particular product. Within these plans resides in-
depth information on machinery, plant resources, equipment layout, configurations, tools, and
instructions.
Engineering Drawings are a type of technical drawing is used to fully and clearly define
requirements for engineered items.
Assembly Drawings show how different parts go together, identify those parts by number, and
have a parts list,
Routing Sheet in a manufacturing or production unit defines the exact process by which a
product is to be manufactured or a service is to be delivered.
Product Hierarchy is the decomposition of a product showing the relationship between parts.
This is used in conjunction with the BOM which additionally shows all
critical product information including lists the raw materials, assemblies, components, parts
and the quantities of each needed to manufacture a product.
LLC - Low-Level Coding refers to the lowest level code of the item used in BOM. The low level
code is registered to each item, and is used to perform a level-by-level explosion.
BOM Processor is data management system that organizes the specifications of product
assemblies and structures used in manufacturing and related industries. Essential component
in most commercial software packages; maintains the BOM and automatically assigns Lowest-
Level Coding (LLCs) — The BOM processor is essential for products with large BOMs (e.g.,
automobiles include approximately 30,000 components)
Process Planning is a plan of how your parts will be produced, what machines to use and in
what order, to achieve the correct tolerances etc. It involves strategic decisions and careful
analysis with production engineers and expertise in order to plan and adapt the production of
every single component.
Orthographic Projection is a means of representing three-dimensional objects in two
dimensions.
Dimensional Tolerances is the permissible limit or limits of variation in: a physical dimension; a measured value or physical property of a material, manufactured object, system, or service; other measured values (such as temperature, humidity, etc.); in engineering and safety, a physical distance or space (tolerance); in mechanical engineering the space (such as between a bolt and a nut or a hole, etc.)
Component Level Design involves the selection, maintenance, design and construction of smaller parts for a larger machine/assembly. This includes selecting, qualifying, approving, documentation, and managing the purchasing of components and direct material required to produce an end product.
Component engineering also involves product lifecycle management plan when a component is going to be obsolete or to analyze the form–fit–functionality changes in the component.
Geometric Tolerances (GD&T) is a system for defining and communicating engineering
tolerances. It uses a symbolic language on engineering drawings and computer-generated
three-dimensional solid models that explicitly describes nominal geometry and its allowable
variation.
Material Properties is an intensive, often quantitative, property of some material
Mechanical Properties is the response of the material to force and load.
Physical Properties is any property that is measurable, whose value describes a state of
a physical system. Physical properties are often referred to as observables.
Thermal Properties is the reaction of the material in the presence of heat or cold.
Electrical Properties is the ability of a material to transmit, store, or impede electricity.
Optical Properties is the ability of the material to transmit, reflect, or absorb light.
Environmental Properties are the ability of the material to maintain performance in its
application environment.
Hardness is the resistance of a material to indentation.
Young's Modulus also known as the elastic modulus, is a measure of the stiffness of a solid
material.
Stainless Steel is a steel alloy with a minimum of 10.5% chromium content by mass. Stainless steel is notable for its corrosion resistance, and it is widely used for food handling and cutlery among many other applications.
Polycarbonates are a group of thermoplastic polymers containing carbonate groups in their
chemical structures. Polycarbonates used in engineering are strong, tough materials, and some
grades are optically transparent.
Resin Transfer Moulding (RTM) is an increasingly common form of molding, using liquid
composites.
Vacuum Assisted Resin Transfer Molding (VARTM) is a closed mold, out of autoclave (OOA)
composite manufacturing process.
Pultrusion is a continuous process for manufacture of composite materials with constant cross-
section.
Hand lay-Up is a molding process where fiber reinforcements are placed by hand then wet with
resin.
Compression Molding is a method of molding in which the molding material, generally
preheated, is first placed in an open, heated mould cavity.